Packaging material



Dec. 31, 19 68 R. J. HAREN 3,419,459

, PACKAGING MATERIAL Filed July 20, 1964 Sheet of 2 IN VEN TOR. %KZD% I #472177,

D 6, 31, 1968 R. J. HAREVN 3,419,459

PACKAGING MATERIAL Filed July 20, 1964 Sheet 2 of 2 7 5; V i 10/ E Q1 2% JIM/5945f United States Patent 3,419,459 PACKAGING MATERIAL Ralph J. Haren, Racine, Wis., assignor to Walker Manufacturing Company, Racine, Wis., a corporation of Delaware Filed July 20, 1964, Ser. No. 383,845 7 Claims. (Cl. 161--134) ABSTRACT OF THE DISCLOSURE A packaging material for making boxes comprises a sheet of container grade paperboard and a support sheet of extensible paperboard secured to it and provided with an array of overlapping, bend resisting, W-shaped indentations that form air cells that resist crushing.

This invention relates generally to packaging materials, and more particularly, to a substantially rigid and crushresistant fiberboard construction.

In general, the fiberboard construction of the present invention comprises an embossed intermediate reinforcing member which is adapted to be fabricated of an extensible type paper board and which is laminated interjacent a pair of outer facing members. The embossments provided in the intermediate member consist of a multiplicity of interlocking embossed ribs or projections which are arranged such that the fiberboard construction is basically rigid in every direction, and which permit the fiberboard construction to be slightly bent or creased without seriously impairing its crush-resistant properties.

It is accordingly a primary object of the present invention to provide an improved crush-resistant fiberboard packaging material.

It is another object of the present invention to provide a packaging material of the above character which, when bent to a shape conforming with an object to be packaged, does not lose its crush-resistant properties.

It is still another object of the present invention to provide a packaging material of the above character of a simple design that may be easily fabricated and economically manufactured.

Other objects and advantages of the present invention will become apparent from the following detailed description taken in conjunction with the accompanying drawings, wherein:

FIGURE 1 is a top elevational view, partially broken away, of an exemplary embodiment of the fiberboard construction of the present invention;

FIGURE 2 is a fragmentary cross-sectional view taken along the line 2-2 of FIGURE 1;

FIGURE 3 is a top elevational view, partially broken away, of another embodiment of the fiberboard construction of the present invention;

FIGURE 4 is a fragmentary cross-sectional view of the structure illustrated in FIGURE 3, taken along the line 4-4 thereof; and

FIGURE 5 is an elevated perspective view of the fiberboard construction illustrated in FIGURE 3, showing the limited flexible properties thereof.

In general, FIGURES 1 and 2 illustrate one embodiment of the present invention, and FIGURES 3 through 5 illustrate another embodiment. The two embodiments are basically similar in construction in that each comprises an embossed intermediate member and two facing members which are afiixed or laminated to the opposite sides of the intermediate member. Preferably, in each of the embodiments described herein, the intermediate member is fabricated of a conventional extensible type paper board and the facing members are fabricated of a container board grade of paper board. As seen in FIGURES 1 and 3, the

arrangement or pattern of the embossments formed in the intermediate members of the two embodiments are generally the same and may be best described as an array of interlocking W or M shaped embossments or ribs which have their respective legs extending parallel to either the transverse or longitudinal axes of the intermediate members. For the purpose of clarity, the transverse axes are from left to right in FIGURES l and 3, and the longitudinal axes are from top to bottom in FIGURES 1 and 3.

The primary difference between the two constructions of the present invention resides in the particular direction in Which the embossments are formed in the respective intermediate members thereof. In the first embodiment (FIGURES 1 and 2), the array of embossments all pro ject or extend away from one side of the intermediate member, and thus upon lamination of the intermediate member between the two outer facing members, the original plane of the intermediate member is substantially coplanar with one of the facing members. In the second embodiment (FIGURES 3 through 5), the array of embossments alternately project or extend away from the opposite sides of the intermediate member and thus upon lamination of the intermediate member between the two outer facing members, the original plane of the intermediate member is spaced approximately equidistant between the planes of the facing members.

Referring now in detail to the embodiment of the present invention illustrated in FIGURES l and 2, a fiberboard construction 10 is shown as comprising spaced parallel facing members 12 and 14 afiixed to the opposite sides of an embossed intermediate member 16. The embossments formed in the members 16 are in the form of an array of interlocking W or M shaped ribs, generally designated 18. As seen in FIGURE 1, each of the cmbossed ribs 18 comprises leg sections 20, 22 and medial sections 24, 26, all of which extend parallel to either the transverse or longitudinal axes of the intermediate member 16. The various sections 20, 22, 24 and 26 of each of the ribs 18 are generally trapezoidal in cross section, and each includes a substantially fiat peak section 28 which is spaced downward from the plane of the intermediate member 16 and is connected thereto by wall sections 30 and 32, as seen in FIGURE 2.

By virtue of the extensible properties of the intermediate member 16, the embossed ribs 18 may be formed therein by compressing this member between a pair of platens which are provided with a complementary array of interlocking W or M shaped projections. Alternatively, the embossed ribs 18 may be formed in the member 16 by passing it between a pair of impressing rolls which are provided with a complementary array of appropriately shaped projections. After thus forming the array of embossments 18 in the intermediate member 16, the member 16 is preferably coated with a sizing material such as silicate of soda or the like, to increase the rigidity thereof and enhance the crush-resistant properties of the fiberboard construction 10. The facing members 12 and 14 may be then glued, laminated or similarly attached to the plurality of peak sections 28 defined by the embossed ribs 18, and to the side of the intermediate member 16 opposite the ribs 18, thereby providing the unitized structure illustrated in FIGURES 1 and 2.

A particular feature of the fiberboard construction 10 resides in the fact that it is substantially rigid or resistant to bending in all directions. This feature is provided by the interlocking arrangement of the array of W or M shaped ribs 18, and is further provided by a plurality of closed air cells which are defined by the plurality of ribs 18, together with those portions of the facing member 14 adjacent the concave sides of the ribs 18. Accordingly, the fiber board construction 10 may find particular use in box making and in related applications wherein a substantially rigid packaging material is required. It may be noted that the above described air cells also function to enhance the crush-resistant properties of the fiberboard construction and thereby enable it to be used in applications where resistance to crushing as well as resistance to bending is required.

Referring now to FIGURES 3 through 5, a fiberboard construction 50, in accordance with an alternate construction of the present invention, comprises a pair of spaced parallel facing members 52 and 54 which are attached to the opposite sides of an embossed intermediate member, generally designated 56. As in the previously described construction 10, the intermediate member 56 is formed with an array of interlocking W or M shaped ribs 58. It will be seen that the ribs 58 are formed in the member 56 in a manner such that every other rib 58 projects or extends from the opposite side of the plane of the member 56 or, as illustrated in FIGURES 3 and 4, ribs 58a extend -or project downwardly from the plane of the member 56, and ribs 58b extend upwardly from the plane of the member 56. Each of the embossed ribs 58 comprises leg sections 60, 62 and medial sections 64, 66, all of which extend substantially parallel to either the transverse or longitudinal axes of the member 56, as seen in FIGURE 3.

The various sections 60, 62, 64 and 66 of each of the embossed ribs 58 are generally trapezoidal in cross section, and the ribs 58a are formed with flat peak sections 68 which are connected to the plane of the member 56 by wall sections 70 and 72, while the ribs 58b are formed with flat peak sections 74 which are connected to the plane of the member 56 by wall sections 76 and 78. As seen in FIGURE 4, the peak sections 68 and 64 define planes which are spaced from and parallel to the original plane of the member 56.

The embossed ribs 58 are preferably formed in the member 56 in the same manner that the ribs 18 were formed in the aforediscussed construction 10, i.e., platens, rollers, or the like, after which the member 56 is preferably coated with a suitable sizing material such as the aforementioned silicate of soda. The facing members 52 and 54 may be thereafter glued or laminated to the plurality of peak sections 74 and 68, respectively, thereby providing the unitized structure illustrated in FIGURES 4 and 5.

A particular advantage of the fiberboard construction 50 over the aforediscussed construction 10 resides in the fact that the latter described construction 50, while being I basically rigid due to the interlocking arrangement of the ribs 58, is slightly flexible and thereby may be bent or curved somewhat to conform with the object being packaged. This limited flexibility is provided by the fact that as the construction 50 is bent, the plurality of sections 60, 62, 64 and 66 of the embossed ribs 58a or 58b which lie along the axis or axes of bending on the concave side of the bend area, will tend to slightly collapse or contract, while the plurality of sections 60, 62, 64 and 66 of the ribs 58a or 58b on the convex side of the bent area will tend to slightly expand It should be noted that as the construction 50 is thus bent, the ribs 58a and 58b will become only partially collapsed such that the construction 50 maintains its crush-resistant properties and continues to cushion the packaged object even after bending. It should be further noted that in the event that a large amount of flexibility is desired in either the fiberboard construction 10 or in the construction 50, the outer facing members 12, 14, or 52, 54 may be fabricated of an extensible paper board of the same type constituting the intermediate members 16 and 56.

While it will be apparent that the preferred embodiments herein illustrated are well calculated to fulfill the objects above stated, it will be appreciated that the invention is susceptible to modification, variation and change without departing from the proper scope or fair meaning of the subjoined claims.

What is claimed is:

1. A substantially rigid packaging material for use in box making comprising at least one outer sheet of container grade paperboard, a support sheet secured to said outer sheet and formed of extensible paperboard, said support sheet being provided with an array of indented portions in the form of nested interlocking substantially W-shaped embossed hollow ribs that are separate and independent of each other and overlap in all directions to provide resistance to bending in all directions, said ribs extending away from said outer sheet, said outer sheet closing the interior of said hollow ribs and forming said ribs into a mass of separate non-communicating closed air cells for crush resistance and cushioning.

2. A material as set forth in claim 1 wherein there are longitudinal and transverse axes, each of said ribs comprising a pair of end sections and a pair of intermediate sections, said end sections and said intermediate sections of each of said embossed ribs extending substantially parallel to one of the axes.

3. A material as set forth in claim 1 wherein each of said ribs is substantially trapezoidal in cross section.

4. A packaging material comprising a pair of outer coextensive sheets of container grade paperboard, an intermediate sheet formed of extensible paperboard and having W-shaped indented portions forming a mass of separate and independent embossed ribs therein acting with at least one of said outer sheets to form a mass of separate closed air cells, said ribs being interlocked and overlapped in all directions to provide resistance to bending in all directions, each of said embossed ribs being defined by a substantially flat peak sections with the plane of said intermediate sheet.

5'. The construction as set forth in claim 4 wherein one of said outer sheets is attached to said peak sections of said embossed ribs and the other of said outer sheets is attached to the side of said intermediate sheet opposite said embossed ribs.

6. The construction as set forth in claim 4 wherein said intermediate member is coated with a rigidifying sizing material.

7. The construction as set forth in claim 4 wherein said ribs project from the opposite sides of said intermediate member.

References Cited UNITED STATES PATENTS 1,240,231 9/1917 Lumley 161137 2,434,466 1/1948 Marc. 2,856,323 10/1958 Gordon l6l131 2,858,247 10/1958 Swart 161131 1,958,050 5/1934 Koppelman 161-l31 FOREIGN PATENTS 622,340 11/1935 Germany.

MORRIS SUSSMAN, Primary Examiner.

US. Cl. X.R.

l6l-l27, 137; 229-6 

